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Old November 18th, 2017, 02:40 PM   #61
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At this point I'm concerned that you may need to disassemble to find what went wrong, this sounds like an assembly issue.
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Old November 18th, 2017, 02:53 PM   #62
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As much as it pains me to agree, I'm afraid you may be right. It's obviously not working correctly as is. Will have to tear down to see if I can troubleshoot and correct the issue.
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Old November 18th, 2017, 03:02 PM   #63
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Ugh... I feel your pain man. I've been there many times. Just take your time and feel free to post follow up questions.
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Old November 18th, 2017, 03:22 PM   #64
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Quote:
Originally Posted by ripyowrist View Post
Also just verified the clutch lever setting as per the manual and checked the secondary adjuster a bit so the screw near the lever isn't at the full extent of its range of travel.

Should all the plates move when looking through the filler hole?
You really want to adjust the lever adjuster to the center of it's adjustment - do a rough final adjust with the secondary adjuster, and then use the lever adjuster for a fine tune. It makes difference even with the stock set up.
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Old November 18th, 2017, 06:55 PM   #65
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Thanks for all the guidance guys. I'm gonna do a slow tear down tomorrow and see what I can find. *Fingers crossed

Also, does anyone have a functioning link to the service manual? I think it might be helpful to see an exploded diagram. I want to verify my placement/order of the washer and sleeve on the back side of the clutch basket on the crank. It seemed like it would only go on one way but want to be sure.

Thanks,

Last edited by ripyowrist; November 18th, 2017 at 08:21 PM.
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Old November 18th, 2017, 09:28 PM   #66
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This is what I've got:
https://www.dropbox.com/s/arylh3bed1...20821.zip?dl=0
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Old November 19th, 2017, 07:20 AM   #67
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I've got more if you need them... the 2015 parts list should be what you want.

I got the bike back together after returning from the bike show, but found a small o-ring under the bench... the inner from the brake lever pivot shaft. So that needs to be replaced before I get a test ride. But the feel at the clutch lever is 100% normal, with the adjuster back where it was before, so I'm hopeful that it will work.

Getting the plates aligned was a slow process of tightening until one binds, then flipping the stack over and loosening & wiggling until it slips into place. Repeat a half dozen times!
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Old November 19th, 2017, 09:35 AM   #68
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It's always something...

I got the bike out for a very brief test ride. Shifted through the gears okay, but couldn't get into neutral at a stop. Started tightening the adjuster, got there once, but the free play was inadequate. So I increased the (aftermarket) lever reach and it got better. Had it at setting 1, fully close. Most importantly, the launch is amazingly smooth now, as promised.

However... the left fork is puking oil, left a puddle on the bench. So it's back on a front stand and the forks will go to Racetech for seals tomorrow. No real test ride today!

Last edited by zippy49; November 19th, 2017 at 09:39 AM. Reason: clarity
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Old November 19th, 2017, 10:46 AM   #69
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Sorry to hear about your forks, but glad to hear your launch is as it should be! I'm sure you'll get your neutral issue sorted .
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Old November 19th, 2017, 12:55 PM   #70
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Ok guys,

I got the thing back apart. At first glance it looks like I doubled up the washers on the drive shaft. Items 13 and 6 in the photo against one another. I had two underneath the sleeve and nothing inside the basket.

Still want to check a few more things before reassembling but I had one other question. Does the top or outermost plate ride pretty freely?

The lower plates seem to be under tension/friction from the springs inside the basket (this with the M3 threaded rod holding everything together) but the top friction plate (one that is offset upon reassembly) and steel plate appear to rotate pretty freely, like there is some play. Is that normal? I think those are the ones that got replaced along with the judder spring.
Attached Thumbnails
2015 Clutch Kits Now Available-clutch.jpg  

Last edited by ripyowrist; November 19th, 2017 at 01:04 PM.
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